Differential Case

DISASSEMBLY
1. REMOVE DIFFERENTIAL RING GEAR





a. Place the matchmarks on the ring gear and the differential case.





b. Remove the 16 bolts.





c. Using a plastic hammer, tap on the ring gear to remove it from the case.
2. REMOVE FRONT DIFFERENTIAL





a. Remove the differential LH case from the differential case assembly.





b. Remove the front differential case form the differential LH case.





c. Remove the front differential side gear, front differential side gear thrust washer, conical spring and center differential side gear thrust washer No.2 from the differential LH case.





d. Using a snap ring expander, remove the snap ring from the front differential case.





e. Using a pin punch and a hammer, drive out the 3 pins.





f. Remove the 3 pinion shafts from the front differential case.





g. Remove the 4 front differential pinions, 4 front differential pinion thrust washers, front differential pinion shaft holder, front differential side gear and front differential side gear thrust washer from the front differential case.





3. REMOVE LH BEARING
Using Special Service Tool (SST), remove the tapered roller bearing.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00060)
4. REMOVE CENTER DIFFERENTIAL





a. Place matchmarks on both the intermediate case and the differential RH case.





b. Using a torx socket wrench, remove the 15 bolts.





c. Remove the intermediate case from the differential RH case.





d. Remove the center differential side gear, the conical spring and the center differential side gear thrust washer No.1 from the differential RH case.





e. Remove the center differential pinion thrust washer, the center differential pinion and the center differential pinion spider from the differential intermediate case.





5. REMOVE RH BEARING
Using SST and a press, remove the tapered roller bearing.
SST 09950-00020, 09950-60010 (09951-00600)





6. REMOVE TRANSAXLE HOUSING SIDE BEARING OUTER RACE
Using SST, remove the outer race.
SST 09308-00010





7. REMOVE TRANSAXLE HOUSING OIL SEAL
Using SST, remove the oil seal from the transaxle housing.
SST 09649-17010, 09950-70010 (09951-07100)





8. REMOVE TRANSAXLE CASE SIDE BEARING OUTER RACE
Using SST, remove the outer race.
SST 09308-00010





9. REMOVE TRANSAXLE CASE OIL SEAL
Using SST, remove the oil seal from the transaxle case.
SST 09649-17010, 09950-70010 (09951-07100)

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with Automatic Transmission Fluid (ATF) before reassembly.





1. INSTALL TRANSAXLE HOUSING SIDE BEARING OUTER RACE
Using Special Service Tool (SST) and a hammer, install the bearing outer race.
SST 09350-32014 (09351-32111), 09950-70010 (09951-07150)





2. INSTALL TRANSAXLE CASE SIDE BEARING OUTER RACE
a. Install the plate washer to the transaxle case.

HINT: First select and install a plate washer of less thickness than before.

b. Using SST and a hammer, install the bearing outer race.
SST 09223-15020, 09950-70010 (09951-07100)
3. INSTALL FRONT DIFFERENTIAL CASE





a. Coat the front differential side gear thrust washer, front differential side gear, front differential pinion shaft holder, 4 front differential pinion thrust washers, the 4 front differential pinions with ATF, install them to the front differential case.





b. Install the 3 pinion shafts to the front differential case.





c. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.002 - 0.008 inch)

NOTICE: Do not mount the surface of front differential case which contacts with bushing in a vise.

If the backlash is not within the specified value, refer to the table and select a thrust washer which will ensure that the backlash is within the specified value.





Thrust washer thickness:





d. Engage the side gear to the above mentioned front differential case.
e. Install the differential case LH to the front differential case and measure its center.
f. After that, remove the differential case LH.





g. Using a straight edge and feeler gauge, measure the clearance between the front differential case and the side gear.
t = Thrust washer thickness
L = Clearance
t = L- 0.17 - 0.26 mm (0.0067 - 0.0102 inch)

HINT: There are 6 thrust washers in different thickness.





Thrust washer thickness:

If the clearance is not within the specified value, parts may have been assembled incorrectly, so check and reassemble it.





h. Using a pin punch and a hammer, install the 3 pins.





i. Using a snap ring expander, install the snap ring.

NOTICE: Be careful not to damage the front differential case.

4. INSTALL DIFFERENTIAL RH CASE





a. Install the center differential side gear thrust washer No.1, conical spring and center differential side gear to the differential RH case.

NOTICE: Install the conical spring with the convex side facing up as shown in the illustration.





b. Install the 5 center differential pinions, 5 center differential pinion thrust washers and the center differential pinion spider to the differential RH case.
5. CHECK CENTER DIFFERENTIAL PINION GEAR BACKLASH OF DIFFERENTIAL RH CASE SIDE





a. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 inch)
If the backlash is not within the specified value, refer to the table and select a thrust washer which satisfied the specified value.





Thrust washer thickness:

6. CHECK CENTER DIFFERENTIAL PINION GEAR BACKLASH OF DIFFERENTIAL INTERMEDIATE CASE SIDE





a. Temporarily install the center differential side gear thrust washer No.2, conical spring, front differential side gear thrust washer, front differential side gear and front differential case assembly to the differential LH case.

NOTICE: Install the conical spring with the convex side facing down as shown in the illustration.





b. Temporarily install the differential intermediate case and 4 bolts to the differential LH case.





c. Install the center differential pinion spider, center differential pinion and center differential thrust washer to the differential intermediate case.





d. Using a dial indicator, measure the thrust clearance of the front differential side gear while holding the front differential case on the No.2 differential case side.
Standard clearance: 0.05 - 0.20 mm (0.002 - 0.008 inch)

HINT: Turning the side gear a bit, check the maximum value of the thrust clearance.

If the backlash is not within the specified value, refer to the table and select a thrust washer which backlash is within the specified value.





Thrust washer thickness:





e. Remove the 4 bolts and the differential intermediate case from the differential LH case.





f. Remove the differential LH case from the from differential case.





g. Install the selected and adjusted center differential side gear thrust washer No.2, conical spring, front differential side gear thrust washer and front differential side gear to the differential LH case.





h. Install the front differential case to the differential LH case.





i. Using a torx socket wrench T50, install the differential RH case to the differential intermediate case.
Torque: 63 Nm (642 kgf-cm, 46 ft. lbs.)
7. CHECK PRELOAD OF DIFFERENTIAL CASE





a. Install the differential LH case and 4 bolts to the differential intermediate case.

NOTICE: Align the matchmarks on the differential LH case and differential intermediate case.





b. Using SST and a press, install the side bearing RR and FR to the differential case.
0SST 09214-76011, 09252-10010, 09316-20011, 09649-17010





c. Install the differential to the T/F case.
d. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transaxle case and the transaxle housing.





e. Install the transaxle housing and 16 bolts to the transaxle case.

HINT: Although the bolt A is a non-reusable seal bolt, in the case, clean the bolts and tighten them as well as the bolts B and C.
Torque: 29.4 Nm (300 kgf-cm, 22 ft. lbs.)

Bolt length:
Bolt A: 50.0 mm (1.969 inch)
Bolt B: 50.0 mm (1.969 inch)
Bolt C: 42.0 mm (1.654 inch)
f. Temporarily install the intermediate shaft.





g. Turn the intermediate shaft right and left 2 or 3 times to allow the bearing settle.
h. Remove the intermediate shaft.





i. Using SST and torque wrench, measure the differential preload.
SST 09564-32011
Preload (at starting)
New bearing: 0.8 - 1.3 Nm (8.0 - 13.4 kgf-cm, 7.1 - 11.5 inch lbs.)
Reused bearing: 0.4 - 0.6 Nm (4.1 - 6.7 kgf-cm, 3.5 - 5.3 inch lbs.)

HINT: If the preload is not within the specified value, refer to the table and select a thrust washer which preload is within the specified value.





Plate washer thickness:





j. Remove the 16 bolts and the transaxle housing.





k. Remove the differential from the transaxle case.
8. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surfaces of the differential case and the ring gear.





b. Heat the ring gear in boiling water.
c. Carefully remove the ring gear from the boiling water.





d. Install the ring gear to the differential.





e. Temporarily install the 8 bolts.





f. Remove the 4 bolts.
g. Temporarily install the 8 bolts.
h. Tighten the 16 bolts.
Torque: 95 Nm (970 kgf-cm, 70 ft. lbs.)





9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
a. Using SST, install the new oil seal.
SST 09608-10010, 09950-70010 (09951-07150)
b. Coat a lip of oil seal with petroleum jelly.
10. INSTALL TRANSAXLE HOUSING OIL SEAL





a. Wind vinyl tape around SST at 6.0 mm (0.236 inch) from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 inch).
SST 09950-60010 (09951-00730)

NOTICE: Clean SST to remove deposited oil, before winding a vinyl tape.

b. Coat the lip of oil seal with petroleum jelly.





c. Using SST, install the new oil seal.
SST 09950-60020 (09951-00730), 09950-70010 (09951-07150)
Oil seal depth: 5.5 - 6.5 mm (0.217 - 0.256 inch)

NOTICE: When the wound vinyl tape contacts the transaxle housing stop press-fitting.